MOULDING DEFECTS

AND
REMEDIES

1
~ HOW MANY KINDS OF DEFECTS ARE THERE?

2
~ HOW MANY KINDS OF DEFECTS ARE
THERE?

31

3
 DEFECTS

1. Sink Marks

2. Streaks

3. Blistering

4. Weld Lines

5. Gloss difference
4
 DEFECTS

6. Jetting

7. Record grooves effect

8. Dull spots near gate area

9. Incompletely filled part ( Short

shots)

10. Diesel effect

5
 DEFECTS

11. Over sprayed parts (Flashes)

12. Stress whitening/Cracking

13. Ejector marks

14. Deformation during demolding

15. Ejection Grooves

6
DEFECTS

7
 DEFECTS

21. Defects on electroplated parts

22. Broken or ragged film hinge
23. Warpage
24. Fish eye

8
 DEFECTS

25. Hesitation

26. Over packing

27. Unbalanced flow

9
28. Nozzle drool
29. Nozzle freeze – off
30 Nozzle spitting
31. Screw slip

10
WHAT ARE THE MAIN FACTORS
CAUSING DEFECTS?

4M?
11
SOME MAIN FACTORS CAUSING DEFECTS

The moulding Machine

Mould
Operating conditions i.e..
Temperature, pressure, injection
speed & time
Material.
Design of product
Management

12
13
 !
"#$%&#

SINK
MARKS

! ! " 14
!
"#$%&#

SINK
MARKS

15
!
"#$%&#

SINK MARKS

16
 !
"#$%&#

Sink
marks

Sink marks on a cylindrical core with poor

temperature control 17
 !
"#$%&#

Sink marks appear as depressions on the surface

of a molded part.
These depressions are typically very small;
however they are often quite visible, because they
reflect light in different directions to the part.

18
 CAUSE OF SINK MARKS

Sink marks occur during the cooling process if

certain areas of the part are not cooled
sufficiently causing them to contract

If these contractions are not compensated and

the outside wall is not stable enough due to
insufficient cooling depressions occur

19
 %' %( % )*& * !
"#$%&#

!
!
! " #

$ %& %&
$ ' (
$ )& "
$ ' (

*+ ,

-+ ' !
!
"
20
.+ /
 !
"#$%&#

Disadvantageous Gating

Solidified Peripheral

Moulded part with sink marks

(Gating at the thin wall)

21
 * !
+(, *(')!
*" *& !
"#$%&#

0+ " &

*+ "

-+ ! & " "

1 ( "

22
 * !
+(, *(')!
*" *& !
"#$%&#

.+ ' 2
+ !
( 3! " (

4+ 3

23
 2. STREAKS
Streaks are the prominent stretchy marks
on the surface of the moldings.

CHARRED STREAKS

MOISTURE STREAKS

AIR STREAKS

COLORED STREAKS

GLASS FIBER STREAKS

24
 2.CHARRED STREAKS

Charred streaks due to excessive residence time in

the plasticising cylinder
25
 2.MOISTURE STREAKS:

Streaks due to excessive moisture content of the

granules

26
 2.AIR STREAKS:

&
27
2.COLOUR STREAKS:

&5 ! !

28
2.COLOUR STREAKS:

& &
29
 -(% !
+&, )&,%#

/ !& 6 31 & ( 7 30
%' %( % )*& *& )&,%#

"
" " 3"

"

" "

!
! 5 3" ! "

31
%' %( % )*& *& )&,%#

" " !

! " (

, 1 "

32
 * !
+(, *(')!
*" *& )&,%#

0+ ! &1 " "

3 % ( %
3

*+ ! "
3 +

33
 * !
+(, *(')!
*" *& )&,%#

-+ !& "
' 1 % " "

.+ & !
! 3

4+ " ""

34
 * !
+(, *(')!
*" *& )&,%#

6. Reduce residence time in material hopper

7. Reduce injection rate

8. Round sharp edges of transitions.

9. Reduce depth of engraving

10. Provide for venting

35
 * !
+(, *(')!
*" *& )&,%#

11. Use smaller colour pigments

12. Check solubility of the used die

13. Use shorter glass fiber

36
 3.BLISTERS

Hollows created on or in the molded part

AIR BUBBLES

0+ & && 37
6 ! ( !( " 7
 3.BLISTERS

Air traps occur when converging flow fronts

surround and trap a bubble of air.

The trapped air can cause

Incomplete filling and packing,
Surface blemish in the final part.
Air trapped in pockets may compress, heat up
and cause burn marks.

38
 3.BLISTERS
(hollows created on or in the molded part)

voids

*+ 8 ( +

39
 3.BLISTERS / BUBBLES

Bubbles

40
3.Bubbles
 3.BLISTERS

DELAMINATION

41
4.Blisters and delamination
%' %( % )*& *&+(! ),&

9 13 " !

!
! 3

8 " &

"

42
* !
+(, *(')!
*" *&+(! ),&

0+

*+ (

-+ 3

.+ &

43
* !
+(, *(')!
*" *&+(! ),&

4+

:+ "

;+ , 1 1

<+ "

44
 4.WELD LINE
(Witness marks of two or more melt flow fronts at their joining
zone)

WELD LINE

= ( ( ! (!
&3 " 31 & +

( !
3( ! 45
%' %( % )*& * .,( (!
",

=(
' (
9 1 &
1 "
=(
' 13 (
! " ( & "

, !(

46
 * !
+(, *(')!
*" *&.,( (!
",

0+ '

*+ '

-+ '

.+ 2

47
 * !
+(, *(')!
*" *&.,( (!
",

4+ 1
5

:+ 8 13 (

;+ 1" 6 1( 1 &
7

<+ 1 !(

48
 5.GLOSS/GLOSS DIFFERENCES

Very glossy impression due to reflection on the polished surface

49
 5.GLOSS/GLOSS DIFFERENCES

Only slightly glossy impression due to reflection on a rough

surface

50
 5.GLOSS/GLOSS DIFFERENCES

" ! ! " 3!
! ( 9 " +
3 !" ! (
"6 ! 7+
! ! "
" " ! ! " 3 " 51
! " "+
5.GLOSS/GLOSS DIFFERENCES

52
5.GLOSS/GLOSS DIFFERENCES

53
%' %( % )*& *&-(* ! ,&," ,

!
! "

" !
!

" ! 3 +"+
( "

9
!

, !

54
* !
+(, *(')!
*" *&-(* ! ,&," ,

0+ !

*+ ! " ( !
" !

-+

.+ 1 " >

55
 6.JETTING
The prominent inhomogeneous snake like strands
on the surface of molding
JETTING
JETTING

? " " " " % " 1

+ 56
 /,))!
"-

Mould filling process in frontal flow and with jetting

!
3 ' ( " '

" ! ( ! 57
1 3! &
 /,))!
"-

THREE EXAMPLE OF JETTING 58

 6.JETTING

Jetting occurs when polymer melt is pushed at a high

velocity through restrictive areas, such as the nozzle,
runner, or gate, into open, thicker areas, without forming
contact with the mold wall. Jetting leads to part weakness,
surface blemishes, and a multiplicity of internal defects.

59
 * !
+(, *(')!
*" *&/
,))!
"-

0+ '

*+ " % (

-+ "

.+ 1 " ( !
13 &
& (

60
 7.RECORD GROOVES EFFECT

8 3! " 1 ! !

#
0+ !
! 2
61
*+ '
7.RECORD GROOVES EFFECT

RECORD GROOVE OR ORANGE PEEL

62
* !
+(, *(')!
*" *&&, *& -&**0, , , )

0+

*+ +

-+ 1

.+ '

4+ 9 '

63
 8.DULL SPOTS IN GATE AREA

" 3
&3
0+ "
*+ " ' +
64
 '(( *) !
" -%),%&,%

!(

" ' " &3

" ! "
' +
" ! 9 3
& " 3 ! ( 3
"3 +
65
 '(( *) !
" -%),%&,%

!(

3 & ( 13
" " ! "
+
!( ( ( !
9 3! +
( 3 !
66
* !
+(, *(')!
*" *& '(( *) !
" -%),%&,%

0+ '

*+ "

-+ ! ! " 13

.+ 1 !"

67
9.INCOMPLETELY FILLED PART (SHORT SHOTS)

SHORT SHOT

! 1 !
3 + 68
 9.INCOMPLETELY FILLED PART (SHORT SHOTS)

INCOMP0LETELY
FILLED

69
9.INCOMPLETELY FILLED PART (SHORT SHOTS)

A short shot is the incomplete filling of a mold cavity

which results in the production of an incomplete part.

The flow freezes off before all of the flow paths have
filled.

70
 %' %( % )*& *& 1*&) 1*)

' 1 6
1 7

, 1 "

' !
!

"

71
%' %( % )*& *& 1*&) 1*)

( % !
3 !1 & ! (

& ! !(
13

!
! " "

72
 * !
+(, *(')!
*" *& 1*&) 1*)

0+ ' %

*+

-+ + !
1

.+ !

73
 * !
+(, *(')!
*" *& 1*&) 1*)

4+ 1 3 1 +

:+ ! 5 11 "
9 13

;+ " "+
! 3 ! 3
% 3@
! % " &
&1 1 3( +
! " ( % "
1

74
 10.DIESEL EFFECT / BURNED MARKS

BURNED MARKS
!
! !! ( 2
1 &+

A " ( !
&3 " 75
3 &3 1& +
10.DIESEL EFFECT / BURNED MARKS

BURN MARKS

BURN MARKS 76
10.DIESEL EFFECT / BURNED MARKS

BURNS

77
BURNS
 10.DIESEL EFFECT / BURNED MARKS

3 1 " & % "

" " "
" & +

& %! % ( &%
( 1 ! (! % !
!( +

78
* !
+(, *(')!
*" *& !
, ,(, , )

0+ " B "

*+ '

-+ '

.+ B

4+ 1 1 31 "+

8 3& 1
( 3( && " &
"
79
 11.FLASHES

FLASHES

! "! % !
1 " 1 % ( ' +
!
( ( & +
80
>1 , C
11.FLASHES

81
 11.FLASHES
Flashing occurs when a thin layer of material is
forced out of the mold cavity at the parting line or
ejector pins location.

This excess material remains attached to the

molded article, and normally has to be manually
removed.

82
11.FLASHES

FLASHES

83
 %' %( % )*& *& (% 1,

, & " ( 9 %
!
! " %9 "
% " "!

"! " (

"

!
! 1 3!

84
 * !
+(, *(')!
*" *& (% 1,

0+

*+ 1 "+ 8 3 1& "

! & "

-+ " ! 3 !
!
3&3D
& "E "

85
 * !
+(, *(')!
*" *& (% 1,

.+ ' &
+

4+ 3& " ( "

! ( "+

:+ 3& "! & "

( 1 +

86
 12.STRESS WHITENING

" " &3 "

&3 9 !
+
3 & &3 &
9 & " !

! F 3
87
( ! 1& +
12.STRESS WHITENING

STRESS WHITENING 88
* !
+(, *(')!
*" *& )&, .1!
),"!
"-

0+ '

*+ 3

-+ 3

.+

89
* !
+(, *(')!
*" *& )&, .1!
),"!
"-

4+

:+ !
3 '

;+ ! 3 3 3
B

<+ ! 3
B

90
 13.EJECTOR MARKS

DEPRESSED EJECTOR
MARKS

'
1 "& " (
3 ! 91
! ! +
 %' , *&,/
, )*&$%&#

" " " !

" !
! (
& ( ( '

, " " "

!

"! " ' "

92
* !
+(, *(')!
*" *&,/
, )*&$%&#

0+ & ! !
'

*+ ! '

-+ " ' "3

.+ "

93
* !
+(, *(')!
*" *&,/
, )*&$%&#

4+ " ' 3

:+ !

;+ "! ! "%
"

94
 14.DEFORMATION DURING DEMOULDING

DEFORMATION

DEFORMATION ON THE MOULDED PART DUE TO FORCED DE MOULDING

&
( 3 " "+
3& & + 95
* !
+(, *(')!
*" *& , *&$%)!
*" '&!
"- ,$*'( !
"-

0+ "

*+ "

-+ "

.+ '

96
* !
+(, *(')!
*" *& , *&$%)!
*" '&!
"- ,$*'( !
"-

4+ ) ! 3 "
!

:+ ! " !
"

;+ ) "

97
 15.EJECTION GROOVES

' " 1 " "

" ! !
+
3 3 ! + 98
 %' , *&,/, )!
*" -&**0,

= !+

! " +

! 9 1 13
+

!
!+

99
* !
+(, *(')!
*" *&,/
, )!
*" -&**0,

0+ "

*+ (

-+ !

.+ ) ( ! "

4+ !
!

100
 16.FLAKING OF SURFACE LAYER

FLAKING

( " ! 3
! " !
! !!101
& "& ( ' 3 +
* !
+(, *(')!
*" *& (%#!
"- * '& % ,(%2,&

0+ ! +
& 3 1
& 3 9 "
&

*+ 3

-+

.+

4+ !
! A "+ " 3
" ! 102
 17.COLD SLUG

COLD SLUG NEAR THE GATE

" ! ( ! 103
" &! 13 ! +
 17.COLD SLUG

WELD LINE BEHIND A COLD SLUG

" ! ( ! 104
" &! 13 ! +
 17.COLD SLUG

FLOW FRONT TRANSFORT THE COLD SLUG IN TO THE MOULD

" ! ( ! 105
" &! 13 ! +
 %' , *& *( ('-

3&

" & &

106
 %' , *& *( ('-

, &

0+ "

*+ " 3

-+

.+ 1 ' & (

107
 18.FILAMENTATION

Long filamentation of a cold runner gating system near the machine

nozzle
!
! " ! "
% & 3! "
+
3 "!
! ! 1 +
" 3 (108
! ! !! +
 18.FILAMENTATION

Long filament near a hot runner gate

!
! " ! "
% & 3! "
+
3 "!
! ! 1 +
" 3 (109
! ! !! +
 * !
+(, *(')!
*" *& !
(%$,")%)!
*"

0+ , 1 !
! " " 3 +

*+ 9 1 " +

-+
! !
+

110
 * !
+(, *(')!
*" *& !
(%$,")%)!
*"

.+ " " +

4+ 3 1 & & !(
" +

:+ +

;+ "

111
 19.DARK SPOTS

& & (
& " 3 1 +
3 &
1" ! ! "
% (1
" + 112
 19.DARK SPOTS

Severe black specks 113

 19.DARK SPOTS

Poor screw flights design ,dead spots lead to black specks

114
 %' , *& %&# *)

# % "%

, &

0+ ! ! +

*+ & +

-+ +

.+ +

115
 %' , *& %&# *)

# % "%

, &
$ 1 5 +

$ , 1 1 +

$ , " "3 +

$ 1 3 +

116
 20.PLATE OUT

ROUGH SURFACE DUE TO PLATE OUT IN THE MOULD

, ! ! ! +"
( 1 3 ! ! 1
+
3
, % ,,%
, A%
,%, )%
, ( 1
! %& 117
&'
 20.PLATE OUT

PLATE OUT NEAR THE GATE

, ! ! ! +"
( 1 3 ! ! 1
+
3
, % ,,%
, A%
,%, )%
, ( 1
! %& 118
&'
 %' , *& (%),*')

" 9 1 ! &

& 3! %& &

+

3" "+

" % 9 1
% % +

119
* !
+(, *(')!
*" *& (%),*')

0+ ) & &

*+ " ! & +

-+ ) ! 3 ! 1"
+

.+ & 3 !& (
1 B B& +

120
* !
+(, *(')!
*" *& (%),*')

4+ 9" +

:+

;+ !
! 1 "+

<+

121
 21.DEFECTS ON ELECTROPLATED PARTS

PIMPLES AND BLISTERS ON A MOULDED PART

! 6 %
& % !
!
3 7
+
! '
1 & +
! ( 122
"+
 21.DEFECTS ON ELECTROPLATED PARTS

BLISTERING DUE TO DRAWN –IN AIR (COMPONENT

WITH AND WITHOUT ELECTROLITIC LAYER)

! 6 %
& % !
!
3 7
+
! '
1 & +
! ( 123
"+
* !
+(, *(')!
*" , , ) *" ,(, )&* (%), %&)

0+ '

*+ ( (
" +

-+ +

124
* !
+(, *(')!
*" , , ) *" ,(, )&* (%), %&)

.+ 1 ( 1 +

4+ 1 ! "

:+ 1 +

;+ "" +

125
22.BROKEN/ RAGGED FILM HINGE

STRESS WHITENING ON A FILM HINGE

" 1" ' +

! & !
+ 126
 22.BROKEN/ RAGGED FILM HINGE

STREE
WHITENING

STRESS WHITENING ON A FILM HINGE

! !! " 3 &3
1 3 +
! " 3& 3
3
+
127
1 " ( "+
* !
+(, *(')!
*" *&+&*#,"3&%--, !
($ 1!
"-,

! ! !

0+ +

*+ ' +

-+ ( +

.+ ( !! "+

4+ ) !(

:+ 1 !" " ( 3! "+

128
* !
+(, *(')!
*" *&+&*#,"3&%--, !
($ 1!
"-,

! ! > "+

0+ (

*+ ) ! ( ! 3

-+ " "

129
* !
+(, *(')!
*" *&+&*#,"3&%--, !
($ 1!
"-,

!& 3 ! !( +

0+ 1( ! ! " +

*+ ( +

-+ ) ! " 1 3

.+ ! ( !! ( !

130
 23.WARPAGE

MOULDED PART WITH WARPAGE ON THE EDGE

" 1 ! !
> +

"%, ( & "

& ( %( %& ( &3
131
! ( "
 23.WARPAGE

WARPAGE

WARPAGE IN THE FLANGE AREA

" 1 ! !
> +

"%, ( & "

& ( %( %& ( &3
! ( " 132
 23.WARPAGE

Variation in mould temperature will cause

component to warp 133
 23.WARPAGE

Warped component
134
 23. WARPAGE

Distortion of the part caused by non-uniform shrinkage of

the plastic.

135
 23.WARPAGE

Typical warpage in most radiator end tanks.

136
 %' %( % )*& *&.%& %-,

Article ejected too hot.

Variation in section thickness or contours of the

screw.

Excessive area discharged or packed into the area

around the gate.

Non-uniform mould temperature due to improper

positioning if the cooling channels in the mould.

Excessive feed.

137
CAUSAL FACTORS FOR WARPAGE

' "+

!
! " +

, 3 " "3 +

)& " (
" +

" +

138
 * !
+(, *(')!
*" *&.%& %-,

0+ ' 6 1 5
% 1 1 "7+ %
1 1 "7+ %
1 1 "7
+

*+ " ! > +

-+ ! "
+

.+ > B& !& 1 +

139
 * !
+(, *(')!
*" *&.%& %-,

4+ ' 5 +

:+ " +

;+ " &
+

<+ 3 " " ' +

140
 24. FISH EYES

Fish eyes are a surface defect that results from

un melted material being pushed with the melt
stream into the cavity and appearing on the surface
of a molded part.

141
 24. FISH EYES

Remedies for Fish eyes

1. Reduce regrind material

Contact material suppliers to get the recommended
levels of regrind to use.

2. Optimize melt temperature

3. Modify screw design

Contact material suppliers to get the right screw
design information to avoid improper melt mix or
overheating that leads to material degradation.
142
 25. HESITATION

Hesitation is when flow slows down or stops along

a particular flow path.
If plastic filling a cavity has the option of filling either
a thin section or a thick section, the plastic will tend
to fill the thick section first as this route offers less
resistance to flow.
Hesitation can occur in ribs and in thin section of
parts that have significant changes in wall
thickness.

143
25. HESITATION

144
 25. HESITATION

Remedies for Hesitation

1. Move the polymer injection location away from

the area of hesitation so that the bulk of the
cavity fills before the melt reaches the thin area.

2. Move the polymer injection location to a place

that will cause greater pressure to be applied
where the hesitation occurred.

145
 25. HESITATION

Remedies for Hesitation

3. It is useful to have thin ribs/bosses as the last

point to fill

4. Increase the wall thickness where the hesitation

occurred, to reduce the resistance to flow.

5. Use a less viscous material

6. Inject more quickly

7. Increase the melt temp

146
 26. OVERPACKING
Over packing is when extra material is compressed
in one flow path while other flow paths are still
filling.

147
26. OVERPACKING

148
 26. OVERPACKING

Remedies for Over packing

1. Thicken or thin parts of the model to act as flow

leaders or deflectors.

2. Move the injection location to a position that will

define similar length flow paths.

3. Divide the cavity into imaginary sections, and

use one injection location for each section.

4. Remove unnecessary gates.

149
 27. UNBALANCED FLOW
Unbalanced flow is plastic completely filling
some flow paths in the mold before other flow
paths have filled.

150
27. UN BALANCED FLOW

151
 27. UN BALANCED FLOW
Remedies for Unbalanced flow

1. By altering the thickness of regions within the

part, flow can be fastened or delayed in
certain directions to help balance flows.

152
28. NOZZLE DROOL

153
28. NOZZLE DROOL

154
29. NOZZLE FREEZE - OFF

155
29. NOZZLE FREEZE - OFF

156
30 . NOZZLE SPITTING

157
31. SCREW SLIP

158